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INDIAN FOUNDRY INDUSTRY
Vikas Garg
President, The Institute of Indian
Foundrymen (IIF)
&
Managing Director, Forace Polymers
About IIF
• Apex Industry body established in 1950
• Active member of WFO
• Accredited Business Member Organization by National Accreditation Board of Education & Training under Quality Council of India.
• Over 4000 members – Leading foundries, Equipment Manufacturers, Material Suppliers, Technology & Service Providers, Academicians & students
IIF Contd….
Four Regional Offices, Three Centres of Excellence &
27 Chapters across India,
Centers of Excellences -
• Centre of Education & Training, Kolkata
• Foundry Informatics Centre, Delhi
• National Centre of Technical Services, Pune
IIF’s Major Activities
Training, Education & Certification
Seminars/ Conferences/ Exhibitions for Dissemination of knowledge.
Publication of Technical Material /CDs / DVD.
Dissemination of Information on Latest Trends/ Technologies Global Best Practices/ Participation in International Events
Business Development.
Business Development
Promotion of Various Govt. Schemes for Benefit of Foundry Sector
Policy Advocacy
Maintenance & Updating of Analytical Database
Awards For Promotion of Excellence in Various Operational Areas of Foundries
Infrastructure at IIF
Large Modern Library at Kolkata
Offices at Kolkata , Delhi ,Pune , Chennai, Coimbatore owned & Maintained by IIF
Secretariat with Supporting Infrastructure
Centres of Excellences
Indian Foundry Industry
at a Glance
3rd LARGEST GLOBALLY
Approx Units : 4600
Production: 10 Million MT PA
Employment: 2 Mn Direct & Indirect
Major Foundry Clusters: 19
Productivity Per unit : 2100 TPA
Avg Productivity/ Man/ PA: 20
Max Productivity / Man/ PA: 90
Indian Foundry Industry Contd..
Exports: USD 2.5 Bn. Additionally USD 2.5 Bn Finished components. Potential to Grow to USD 12-15 Bn in next 7-10 years.
Outlook: Needs to Grow 3 folds producing 30 Mn Tons/PA in next 10 years to support “Make in India”
Investments Needed : USD 6-8 Bn in 10 years
Business Environment & Economy
Government focusing on “Make in India”, Ease of doing business, infrastructure & easing FDI norms to promote investments in manufacturing & new initiatives & co operations in skill development.
Forecasts of growth by leading institutions :-
India to become fastest growing economy as per forecasts of IMF & World Bank & likely to outpace China
2014 2015 2016
% Annual Growth 7.2 7.5 7.9
Types of Castings Produced
The Institute of Indian Foundrymen..
2004-05
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
2011-12
2012-13
2013-14
Grey C.I. 3.18 4.116 4.87 5.332 4.532 5.05 6.18 6.798 6.254 6.7
SG Iron 0.442 0.618 0.762 0.802 0.785 0.8 0.984 1.09 0.981 1.000
Malleable 0.04 0 0.0623 0.0651 0.0605 0.0602 0.0692 0.066 0.0604 0.060
Steel 0.581 0.805 0.914 0.964 0.916 0.88 1.07 1.14 1.158 1.100
non ferrous 0.38 0.516 0.571 0.608 0.547 0.653 0.75 0.9 0.891 0.95
TOTAL 4.623 6.055 7.1793 7.7711 6.8405 7.4432 9.0532 9.994 9.3444 9.810
0
2
4
6
8
10
12
Production of Castings Mn Tons
1395.14
2054.42 2174.34 2128.19
743.28
996.58 873.63 826.69
121.59 201.02 179.32 135.55
0
500
1000
1500
2000
2500
2010-11 2011-12 2012-13 2013-14
Export Total Import Import from (China)
Export of Major Castings from India / Import of castings in USD Million
Auto Sector –Major Consumer
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
2008-09 2009-10 2010-11 2011-12 2012-13 2013-14
Trends in Auto Sector
Passenger Vehicles Commercial Vehicles Three Wheelers Two Wheelers Grand Total
Category 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
Passenger Vehicles
23,57,411 29,82,772 31,46,069 32,31,058 30,87,973 32,20,172
Commercial Vehicles
5,67,556 7,60,735 9,29,136 8,32,649 6,99,035 6,97,083
Three Wheelers 6,19,194 7,99,553 8,79,289 8,39,748 8,30,108 9,49,021
Two Wheelers 1,05,12,903 1,33,49,349 1,54,27,532 1,57,44,156
1,68,83,049
1,84,99,970
Grand Total 1,40,57,064 1,78,92,409 2,03,82,026 2,06,47,611 2,15,00,165 2,33,66,246
s
Forecast-
Tractors (000)
0
200
400
600
800
1000
1200
2009-10 2010-11 2011-12 2012-13 2015-16 2020-21
420
545 640 641
710
1000
Major Foundry Clusters
Following major foundry Clusters are formed under IIUS
(Industrial Infrastructure upgradation scheme of Ministry of Commerce & Industry for clusters )
Belgaum
Coimbatore
Kolhapur
Howrah
Common Facilities in clusters
Foundry Simulation softwares
Promote Green & Clean Environment
Improvement in Basic infrastructure
Common interactive portal for members
ERP software package for members
Common Training facilities
Common Testing labs
Vendor/supplier development programme
Collective procurement where possible
Common Facilities in clusters
Modern Convention Hall
Optical Emission Spectrometer
3 D CMM Machine
Sand Reclamation
3 D Modelling & ERP /CAD CAM solutions
Modern Tool room
Rapid Product Development
Benefits
Access to common Modern Design, Production & Testing facilities
Improved productivity
Improved skills
Better infrastructure
Collective bargaining for procurement & other services
Greener environment
Improved profitability & overall improved competitiveness
New Initiatives
Lean Manufacturing Programme undertaken with National Productivity Council
UNIDO-GEF Programme for Energy Efficiency
UNIDO ICAMT Project for improved productivity in cluster
UNIDO- ( United Nations Industrial Development organization )
GEF-Global Environment Fecility
ICAMT-International Centre for the Advancement of Manufacturing Technology
IIF Initiatives
IIF is promoting the energy conservation in foundries by conducting awareness programmes /detailed energy audits supported under UNDP/GEF SGP
Signed MoU with Central Board of Secondary Education for introducing foundry Technology in schools as an optional vocational subject
UNDP-United Nation Development Programme
GEF-Global Env Facility
SGP-Small Grants Programme
Future Plans
To Promote Health & Safety in foundries. Initiated dialogue
with National Safety Council.
To Promote recycling of foundry sand in clusters & to take
up with Govt. to support this to protect environment &
conservation of natural resources.
To promote collaborative approach in clusters for improved
competitiveness.
Conclusion
India Foundries are increasingly focusing on :-
Lean Manufacturing for improved productivity
Value addition & cost competitiveness
Energy efficiency & conservation of natural resources
Recycling & Waste Reduction
Indian foundries are capable of producing value added engineered castings (From a few grams to over 100 Tons/piece) for various applications conforming to international standards at internationally competitive prices.
Conclusion Contd….
The business sentiment has considerably improved in the last 3 months
The new Govt. has a strong mandate for economic development.
Increased focus of Govt. on investments by allowing higher FDI limits & incentives for investments in plant & machinery for manufacturing for limited period.
Increased focus on manufacturing, skilling.
Fast tracking of projects & removal of procedural bottlenecks & emphasis on e governance.
Promoting “Make in India” by facilitating ease of doing business.